Automatic apparatus for storing and dispensing packaged medication and other small elements

ABSTRACT

The system includes a bin hopper which temporarily stores a plurality of small elements, such as medications. The elements are moved out of the bin and singulated into a one-by-one sequence by a series of singulating conveyors. The resulting sequence of elements is moved onto a main system conveyor where the element is identified and then moved to a loading mechanism which arranges the item so it is ready to be gripped and stored. The system includes a mass storage apparatus comprising a series of four upstanding cylindrical drums, each having a plurality of individually accessible and addressable cell storage locations for the elements. A gripping apparatus removes the elements from the loading mechanism and transfers them to a selected location in a cylindrical drum. When an article is to be dispensed, the drum is rotated so that an ejection arm comes adjacent the desired location in the drum. The ejector arm is actuated, pushing the small element out of its slot, into the center of the drum, where it falls onto a conveyor which moves the dispensed item from the system.

TECHNICAL FIELD

This invention relates generally to an apparatus for automaticallyreceiving individually packaged medical elements, such as medications,as well as other small, packaged elements into a storage container,singulating the elements from the storage container, processing theelements for storage in individually accessible locations in a massstorage system and retrieving the stored elements from the mass storagesystem individually upon command.

BACKGROUND OF THE INVENTION

There are many known systems for storing and dispensing medications andother small elements. Some of these systems are entirely mechanical,with selections by the user being made by hand. Other, more recentsystems are either semiautomatic or automatic, with electroniccontrollers. Examples of such apparatus are shown in U.S. Pat. No.4,546,901 to Buharazzi and U.S. Pat. No. 5,797,515 to Lift et al.Another apparatus is shown in U.S. Pat. No. 6,219,587, which is assignedto the assignee of the present invention.

The systems shown in the above patents, as well as other dispensingsystems, have met with varying degrees of operational success and/orcommercial acceptance. Most of the automated systems are complex indesign and operation, relatively large and typically quite expensive.Further, many such systems are inefficient and unreliable. They also aretoo slow in output. For instance, typical known commercial systems areunable to meet the medication-dispensing requirements of a largehospital.

One significant disadvantage of conventional automatic dispensingsystems is that they typically must be loaded by hand. Some systemsinclude tubes or storage sleeves which contain a plurality of one item,but these must be periodically replaced, again by hand. In othersystems, the individual items/elements to be dispensed must behand-loaded on racks or hand-placed into bins.

Further, many dispensing systems are inherently limited to either one ora relatively few packaging configurations. This is typical if theelements are in the original manufacturer's package. In other cases, theoriginal elements are either repackaged or overpackaged foraccommodation by the system. The small number of different-sized boxeswhich can be accommodated by a particular system is a key operationalconsideration. Both repackaging and overpackaging, however, areinconvenient, expensive and time-consuming, even when carried out at thehealthcare facility or other facility which uses small packagedelements. There is typically a significant ambiguity if not antipathyrelative to, for example, overpackaging carried out at a user'sfacility.

Lastly, in all medication-dispensing systems, as well as for otherpackaged elements, there exists the issue of returned elements whichhave not been used. These returns must typically be inspected and thenloaded, again by hand, if suitable for restocking. In some cases,returns are handled completely separately, with the returns supplying aseparate storage device apart from the main dispensing system.

It would be convenient and cost effective to have a single machine whichcould accept returns, along with original items from the manufacturer,process and store all the items automatically, and then dispense themautomatically upon command, i.e. a single apparatus which has thecapability of both storing elements, including, but not limited to,medications and other medical elements, and then dispensing themindividually for use by a patient or other user.

SUMMARY OF THE INVENTION

Accordingly, the present invention is a system for automatically storingand dispensing individual elements, comprising: a bin for temporarilystoring a plurality of individual elements and for depositing them oneby one onto a system conveyor member which in operation moves theelements to a loading mechanism; a loading mechanism for removing theitem from the conveyor and positioning it so that it is ready to bestored; a mass storage apparatus containing a plurality of individuallyaddressable storage locations for storage of said elements; an assemblyfor moving the positioned elements individually in turn and storing eachelement in a preselected location in the mass storage apparatus; and atleast one dispensing assembly for removing a selected individual elementfrom a known location in the mass storage apparatus and for moving thedispensed element out of the system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of the complete system of the presentinvention, including an input hopper portion and an external conveyorapparatus.

FIG. 2 is a top view showing the input hopper of the system of FIG. 1,including an input stair stepper part thereof.

FIG. 3 is a diagram showing the operational sequence of the stairstepper portion of FIG. 2.

FIGS. 4–6 are several views showing the input handling of the inputelements to be stored and dispensed, including singulation thereof fordelivery to a main conveyor of the sorting/dispensing system of FIG. 1.

FIG. 7 is a simplified diagram showing the basic operational layout ofthe system of FIG. 1.

FIG. 8 is a top view showing a scan zone portion of the system of FIG.1, which follows the singulation of the input packaged elements.

FIG. 9 is a top view showing the main conveyor of the system of FIG. 11from the singulator exit gate to the end thereof.

FIGS. 10–11 are top views showing the loading platform of the system ofFIG. 1, including various steps in the sequence of operation thereof.

FIGS. 12–13 show views of the gripper portion of the system of FIG. 1,including the movement of packaged elements from the loading platforminto the drum storage assemblies.

FIG. 14 shows the element ejector portion of the system of FIG. 1 forejecting stored elements into an output conveyor for delivery out of thesystem.

BEST MODE FOR CARRYING OUT THE INVENTION

The system of the present invention is an automatic storing anddispensing apparatus for small packaged elements, shown generally at 10,which includes an input container 12, also referred to as an inputhopper, for receiving small packaged elements, such as medications,processing and then moving them into a mass storage portion of thesystem, comprising drum storage assemblies 14.

The individual elements, following their introduction into theapparatus, are first singulated and then moved to a loading assembly,where they are oriented, picked up by a gripper assembly 16, and movedinto a selected location in drum storage assemblies 14. The embodimentshown comprises four drum storage assemblies, each assembly being acylinder having a plurality of individually addressable/accessible slotstherein, open on the exterior of the drum, for storing of individualpackaged elements. The drum storage assemblies 14 are in the embodimentshown individually rotatable under computer control, as is the gripperassembly 16 which moves the individual elements into the storagedevices. Each slot in the drum storage devices is uniquely identifiedand accessed.

The present system also includes two ejector mechanisms 18 which in theembodiment shown are located, respectively, between two adjacent drumstorage assemblies, the ejector mechanisms each having the capability ofaccessing each cell in the two drum storage assemblies they service, bymeans of rotation of the drum storage assemblies and vertical movementof the ejector mechanism. The ejector mechanism includes a pusher memberwhich operates to push the stored element in the accessed cell in thedrum storage assembly toward the open center thereof. The ejectedelements fall down the open center area of the drum assembly and onto anexit conveyor, are moved out of the system by the conveyor, and thenonto a next stage apparatus, which in some cases could be an elementhandling conveyor 22 which will move the elements directly into amedication cart or to a loading device. The filled cart is ready fordelivery to the patients, such as on a hospital ward (not shown).

Referring now to the drawings in detail, the apparatus 10 is capable ofreceiving packaged medications or other elements in bulk through asingle inlet 20, similar to a mailbox door, the receivedmedications/elements including returns of all types. The apparatus isoperative to identify the element/return and move it to a storedlocation in the mass storage system. The system is also operative toaccess selected elements in the storage assemblies when selectedelements are desired for dispersal.

These actions can be done in a very rapid manner, approximately sevenoperations per minute, in a reliable manner, by the embodiment shown.The cost of the present system, even with its substantial operationalcapability, is well below similar commercially available systems.

The input portion of the system of the present invention, referred to asinput hopper 12, includes a large, curved, slidable opening 20 at thetop end thereof, approximately 16 inches long by 8 inches wide in theembodiment shown. Input hopper 12 is capable of handling up to 750individual items, depending upon the size of the package elements, andis further capable of receiving a large number (250) at one time throughopening 20.

The system of the present invention is capable of handling a variety ofelements. Medications is one category, including oral medications, suchas tablets and pills and liquid elements, as well as medical elementssuch as syringes. The system can also be used with other elements whichare relatively small in size. This can include a wide variety ofhardware parts, jewelry items of various kinds, and even food items.

Hence, the present invention is thus not limited to a particular type ofelement, although it has proven to be useful with medication-typeelements.

Further, while the input may desirably be in the form of overpackagedelements, such as in particular boxes of selected sizes, with particularconfigurations, into which is positioned the individual packaged (orunpackaged) elements as they come from the manufacturer, it should beunderstood that the apparatus is also capable of handling elementsreceived as is from the manufacturer. For medications and otherelements, for instance, these manufacturers' products could includeblister packs and pouches of various configurations for various solidmedications, as well as vials, syringes and bulk medications. Euclidpackages could be included, as well as liquid cups for handling unitdoses of bulk liquids, strip packages of various sizes and arrangements,and boxes provided by the manufacturer. The flexibility of the presentsystem, in its various arrangements, allows, if desired, the facilityusing the system, such as a hospital, to omit overpackaging (in whichthe individual element, even a packaged element, received from themanufacturer is inserted into a new package/box); and/or repackaging, inwhich the individual element, received from the manufacturer, is removedfrom the manufacturer's package and put in a new package.

The present system is described using boxes; some of the alternativepackaging mentioned above will require modification of some of thestructure of FIG. 1. Alternative structures will be discussed at theappropriate place below.

The input hopper 12 in the embodiment shown is a four-sided stainlesssteel box 27 inches wide by 21 inches long and 22 inches deep. Thesedimensions can, of course, be changed, but the present size isconvenient for the system of the present invention and, as indicatedabove, accommodates approximately 700 small packaged items, which is asubstantial number. While in the embodiment shown the hopper 28 is madefrom stainless steel, other materials could be used. The hopper couldalso have a different configuration.

Two adjacent interior walls 30 and 31 of the hopper are flat andvertical, while the other two walls 33 and 34 are also flat, although aportion of wall 33 extends downwardly and inwardly at an angle ofapproximately 30°, while a portion of wall 34 extends inwardly atapproximately 45°. The angled portions of walls 33 and 34 beginapproximately at or a short distance below the top edges of each wall.

Extending from the bottom 37 of hopper 20 to the upper edge of thehopper is a stairstep mechanism 38 for moving boxes 44 upwardly.Mechanism 38 exits hopper 28 through an opening 40 in wall 34. In theembodiment shown, opening 40 is nearly square, approximately 6⅞ inchesby 7 inches. The stairstep mechanism 38 comprises a set of stationaryplates 42 and a set of moving plates 43, each set consisting of eightstationary and eight vertically oriented metal plates. The stationaryplates alternate with the moving plates. The stationary plates 42 remainfixed, while the alternate moving plates 43 move in both the X and Ydirections (forwardly and upwardly). Pneumatic cylinders (not shown) areused to drive moving plates 43 in both the X and Y directions. Each stepin plates 42 and 43 in the embodiment shown has dimensions ofapproximately 3½ inches (vertical) by 6½ inches (horizontal). The movingplates in the embodiment shown move approximately 75 mm in the X(forward) direction and 50 mm in the Y (upward) direction in eachmovement cycle.

In the embodiment shown, each plate in both the stationary and movingsets is approximately ⅜ inches thick. Three stairs are defined in eachplate in the embodiment shown. There could be fewer or greater number ofstairs, depending upon the particular application. The stairstepmechanism moves individual cartons 44 up and out of the hopper 28.

FIGS. 3A–3E show the sequence of the stairstep mechanism as the movingplates 43 move in X and Y directions relative to the fixed plates 42. Asindicated above, in the embodiment shown, there are eight stationarystair plates 42 in registry across the hopper. Eight moving stair plates43 are arranged to alternate with the stationary stair plates. FIGS.3A–3E show three stationary and moving sets of plates defining threeindividual stairs. The number of defined stairs can vary. The actualphysical dimensions of the stationary and moving stair plates also willvary, depending upon the actual configuration of the hopper.

FIG. 3A shows the moving stair plates 43 at their lowest point ofoperation. In the first action in the sequence, the moving plates 43will be moved upwardly. Again, in the embodiment shown, this isapproximately 50 mm, and is shown in FIG. 3B of the sequence. In FIG.3C, the moving stair plates are moved forwardly in the X direction,approximately 75 mm. At this point, a package (carton) 44 has beenlifted from the bottom of the hopper to the top of the stairstepmechanism. In FIG. 3D, the moving plates 43 move downwardly a distanceof 50 mm and then, as shown in FIG. 3E, move horizontally back to thestarting position.

The number of actual stairs in the stairstep mechanism 38 can be varieddepending upon the distance to be covered. The stairstep mechanism 38does provide a reliable arrangement for beginning the separation of theindividual packages and for moving them out of the hopper. Other systemsto accomplish such a result could be used, however.

In the embodiment described in detail herein, the medical elements aregenerally overpackaged with boxes. However, other packaging arrangementscan be used, with some modification of the system, which will be brieflydescribed relative to the scope of the inventive concept. For instance,in addition to boxes, bags of various sizes can be used, as well ascups, blister packs, euclid packs and syringes, as discussed above.

Referring to FIG. 4, the stairstep mechanism 38 operates until thepackages reach the top thereof, at which point the forward movement ofthe stairstep pitches the packages onto a first conveyor portion 48 of asingulator assembly structure in which the packages are separated fromeach other longitudinally. The singulator assembly in the embodimentshown comprises a series of successive conveyors, referred to as aconveyor system. The first conveyor 48, also referred to as a bufferconveyor, is approximately 6 inches wide by 8 inches long and moves at aspeed of 10 inches per second, driven by a series of pneumatic cylinders(not shown).

Following the first conveyor 48 is a cylindrical conveyor 50, referredto as a speed-up roller. Speed-up roller 50 is responsible for producinga gap between each successive package present on conveyor 48, so thateach package enters the next portion of the conveying system one at atime. Speed-up roller 50 is 6 inches long by 2 inches in diameter andmoves at the rate of 15 inches per second. Speed-up roller 50 passes theitems to a singulating conveyor 52.

Singulating conveyor 52 is also 6 inches wide by 8 inches long andoperates at specified times under computer control at 20 inches persecond, by pneumatic cylinders. The buffer conveyor 48, the speed-uproller 50 and the singulating conveyor 52 are all basically co-planarand horizontal. The singulating conveyor 52 moves the items to avertical conveyor 54, which is positioned at the far end of the singularconveyor 52, extending across the far end thereof and for a distance of5¾ inches beyond edge 56 of the singulating conveyor. The verticalconveyor 54 is 6 inches high and approximately 16 inches long in theembodiment shown, and runs at specified times under computer control at10 inches per second.

Extending from edge 56 of the singulating conveyor 52, with a width ofapproximately 6 inches, is a short, fixed metal ramp 58. In theembodiment shown, ramp 58 is approximately 7 inches long by 3⅜ incheswide and has a downward angle of approximately 22°. This angle can varyto some extent, but is designed to conveniently allow the packagedelements to slide onto an adjacent ramp conveyor 60, aided by the actionof vertical conveyor 54.

In the package singulating process, in the event that two items moveonto singulating conveyor 52 simultaneously, the action of the verticalconveyor 54 will usually separate the two items by virtue of the 90°directional change from the singulating conveyor onto the ramp 58. Theramp conveyor 60 moves in a direction 180° relative to, i.e. theopposite direction from, conveyors 48 and 52. It is approximately 6inches wide by 16 inches long and is oriented downwardly at an angle ofapproximately preferably 10°, within a range of 9°–11°. The verticalconveyor 54 extends to approximately half the width of the rampconveyor. Ramp conveyor 60 is bounded by a short wall 64 along its faredge 65, and also by a short wall 67 along an end portion of its nearedge 69.

Extending from wall 67 is an angled plate 70 which extends for a shortdistance over the surface of ramp conveyor 60. Angled plate 70 assistsin the movement of packages off of the ramp conveyor 60, but is notnecessary to operation of the conveying process. The items move off ofthe ramp conveyor 60 onto a main conveyor 74 which extends in theembodiment at a right angle relative to the ramp conveyor, into the nextportion of the system.

The operation of conveyors 48, 52, 54, 60 and speedup roller 50 iscontrolled by a series of sensors 62—62 (one for each conveyor) locatedgenerally as shown in FIG. 4 and computer-controlled commands. Eachconveyor in the system is initiated at its stated speed when the sensorfor the next downstream conveyor determines that there is nopackage/element present at that conveyor. For instance, if the sensor 62for speed-up roller 50 determines that there is no package present atthe roller, then the prior conveyor, buffer conveyor 48, will beactivated and will operate at its regular speed to move the package tothe speed-up roller 50. This process operates in sequence downstream toramp conveyor 60. The system operates basically on a queue system, i.e.where there is an opening at one conveyor, the immediate prior conveyoris activated. This results in controlled movement of the packagesthrough the singulating system from the time they are moved onto bufferconveyor 48. By the time the boxes reach the ramp conveyor 60, they aresingulated, i.e. they move one by one onto main conveyor 74.

The embodiment shown is effective to singulate individual boxes and willlikely be effective with syringes and even cups. For the blister packs,euclid packs and bags, however, a two-axis gantry vacuum pick system forpicking the individual units would be effective.

When the packages move onto main conveyor 74, they are first measuredand oriented on the conveyor. Along the far edge 76 of the main conveyoris a singulator wall 78. Singulator wall 78 in the embodiment shown isapproximately 9½ inches long by 2 inches high. A singulator shuttleassembly 80 with a shuttle arm 81 is positioned along the far side edge65 of ramp conveyor 60 and across the end 79 of the ramp conveyoradjacent the main conveyor. The portion of the shuttle assembly whichextends across the end of the ramp conveyor 60 is referred to as analignment bar section 83.

In operation, the packages/items will fall over the alignment barportion 83 onto the main conveyor. When an item moves onto the mainconveyor, the singulator shuttle assembly 80 is activated, moving thealignment bar 83 in a sweeping motion across the main conveyor 74. Sincethe main conveyor continuously runs, the item will also be movingforward on the main conveyor as the alignment bar 83 moves it across themain conveyor to contact the singulator wall 78. Alternatively, theconveyor 74 could be controlled for interrupted conveying, at selectedtimes, instead of continuous conveying. Interrupted conveying may bemore effective for certain types of packages, such as bags and blisterpacks and Euclid packs.

The forward movement of the item is stopped by a singulator exit gate84, which extends across the main conveyor but a slight distance aboveit, permitting the main conveyor to run without interference. Theindividual items thus become oriented against the singulator wall andthe singulator exit gate by action of alignment bar 83 and the forwardmoving main conveyor.

The singulator shuttle system 80 includes a potentiometer 85 at the endof an extending arm adjacent shuttle arm 81 controlled by a pneumaticcylinder 87. the potentiometer extends to the item which has beenpressed against wall 78 by action of the singulator shuttle assembly.The contact with the item by the potentiometer produces a reading(depending upon the distance the potentiometer extends) which is thencompared against a look-up table which contains permissible sizes. Ifthe size of the article is out of tolerance for any reasons, such as bydamage to the package, singulator wall 78 is raised and the item ispushed into a singulator reject bin 86 by further movement of alignmentbar 83.

As the item is moved on conveyor 74, against wall 78, a sensor 89measures the height of the item. If the item is too high, a singulatortipper pin 88 located in singulator wall 78 at the far edge 76 of themain conveyor is activated, moving horizontally outwardly across themain conveyor, knocking the tall-standing item over on the conveyor. Theshuttle assembly is used to again align the item on the conveyor. In theembodiment shown, pin 88 is approximately 2¼ inches long and locatedapproximately 1½ inches above the surface of the main conveyor 74.

The identification and orientation/registration of the item on theconveyor in the embodiment described is basically bymechanical/electrical means involving the use of a singulator shuttlegate and an extending potentiometer assembly, positioning the itemssuccessively against the singulator structure. However, other devicescan be used to identify the item and ensure that it meets specifiedstandards, and that it is aligned/registered appropriately. One suchalternative is a visual sensor system, involving a camera which wouldimage the item. Well-known imaging processing technology can then beused to fully identify the item and ensure that it meets specifiedstandards, including size. Other mechanical devices could also be used,such as extending finger-type systems which contact each of the surfacesof the item to determine size. The sensor arrangement would beparticularly suitable for bags, blister packs and Euclid packs.

Immediately downstream of the singulator exit gate 84 is a bar code scansystem 94 (FIG. 8). The bar code scan system 94 includes four bar codereaders 96—96 mounted on a frame 97, which is positioned above the mainconveyor 74. The four bar code readers look for bar codes on the foursides of the item. They can also see the top surface as well. The bottomsurface of the item (the surface contacting the conveyor) is not scannedby the bar code system 94. The bottom surface is scanned in a downstreamportion of the invention, as will be explained hereinafter. If a barcode is recognized by the bar code scan system 94, it is transmitted tothe control portion of the system.

After passing under the bar code scan system 94, the package/item isconveyed by the main conveyor 74 to a depot staging gate 100. In theembodiment shown, the main conveyor, which runs continuously, isapproximately 6 inches wide and 55 inches long and runs at approximately10 inches per second. The depot staging gate 100 is located at adistance of approximately 13 inches forward of the singulator exit gate84. The main conveyor 74 extends from the ramp conveyor to near the exitof the system.

The next portion of the system, downstream from the depot staging gate,is a load platform assembly, shown in FIGS. 9–11. The load platformassembly is referred to generally at 101. When there is an item stoppedby the depot staging gate, a load platform sensor (not shown) firstdetermines whether or not horizontal load platform 110 is “clear”, i.e.that there is no item presently in position on the load platform. If theload platform 110 is clear, the depot staging gate 100 will be raisedand the item will be moved by the main conveyor to the depot stop gate104, which extends across the main conveyor 74 at the far edge of theload platform.

A transfer shuttle arm 106 extends for approximately 7½ inches along themain conveyor across from the load platform. Once the item is stopped bythe depot stop gate 104, the transfer shuttle 106 is activated and movesto contact the item. A potentiometer 107 and air cylinder 109 are usedto measure the box/item again. A laser 111 is used to find the edge ofthe box. The box is pushed onto the platform portion 110 of the loadplatform assembly. In the embodiment shown, the platform 110 is madefrom acrylic plastic and has dimensions of approximately 6 inches by 3½inches.

Located beneath platform 110 is a lift plate 112 which has approximatelythe same exterior dimensions as platform 110. The lift plate 112 has aplurality of pins 113 (FIG. 9) which are mounted in the upper surface ofthe lift platform and extend upwardly therefrom. The pins areapproximately 10 mm high in the embodiment shown. The platform 110 has aplurality of openings therethrough which are in registry with pins 113in lift plate 112. Lift plate 112 is controlled by a pneumatic actuator(not shown), which moves the platform up and down. When the lift plate112 is in its lowered position, the upper surface of load platform 110is flat and co-planar with the main conveyor surface (FIG. 11),permitting an item from the main conveyor to be pushed directly onto theplatform 110.

When the lift platform 112 is in its elevated position (FIGS. 9 and 10),pins 113 extend upwardly through the load platform, above the uppersurface of the load platform 110 by approximately 5–7 mm. The pins 113are located so as to be able to reliably support the item on theplatform and to lift it above the surface of platform 110. This providesroom for the item to be initially gripped by the gripper mechanism,which is explained in more detail hereinafter.

As indicated above, the main conveyor 74 moves items down to the depotstop gate 104, either with continuous movement or interrupted (stop andstart) movement. When an item is sensed at the depot stop gate by asensor (not shown), the transfer shuttle arm 106 is activated and movesacross the main conveyor 74, pushing the queued item which is againstthe depot stop gate 104 onto platform 110. If a barcode has not beenpreviously sensed for the item, i.e. it is on the bottom surface, thelift platform 112 will first transfer out of the way to permit aconventional scan head 118 positioned therebeneath to read the bottomsurface of the item. If a barcode is recognized, it is registered withthe system control, and the sequence of operations will continue. If nobarcode is recognized, then that item is removed from the platform 110by a transfer bar 119, operated by a pneumatic cylinder 121, which movesthe item back onto the main conveyor. The main conveyor 74 will thenmove the item against the depot stop gate 104, which will lift up, andthe item will then be moved to the far end of the main conveyor onto areject ramp 120, down which the item will slide, depositing it into asecond reject box 122.

If a barcode has previously been recognized and registered, or if abarcode is recognized by barcode scanner 118 in the load platformassembly, the lift platform 112 is moved back to its original position.A slot number in one of the drum storage element 14—14 is at this pointassigned to the element by the system controller. As indicated above,when the lift platform 112 is activated and is in its elevated position,pins 113 extend through the load platform 110, lifting the item off ofthe surface of the load platform. Once the pins 113 extend throughplatform 110 to lift the item, the transfer shuttle 106 and the depotstop gate 104 are both retracted to allow the gripping and storingassembly to get into position and to allow opposed grip elements 148 tograsp the item.

FIGS. 9, 10 and 13, 14 show the gripping and storing assembly of thepresent invention. As indicated above with respect to FIG. 1, thepresent invention includes a single gripping and storing assembly whichservices four drum storage assemblies 14—14. Each drum storage assemblyincludes a plurality of individual horizontal slots which are open atboth the front and rear ends thereof. Each drum storage assembly is inthe shape of a cylinder which is open at the center thereof. Thecylinder includes a plurality of ring portions (shelves) which arestacked in a vertical sequence, separated by vertical walls. The ringsand walls define individual slots. The spacing between the rings and thewalls may be varied to define different size and configured storageslots. In the embodiment shown, four different size slots are shown. Thearrangement, size and configuration of the storage slots can be changedto accommodate the size of the elements and the particular elements tobe stored. For instance, the individual slots will differ in sizedepending on the particular package to be stored, e.g. bags, boxes,packs or syringes, among others.

In the embodiment shown for boxes, the outer diameter of the drumstorage devices 14 is approximately 19 inches, while the inner diameteris approximately 14 inches. In the embodiment shown, each drum storageassembly is made out of metal or similar rigid material. Each drumstorage assembly is rotatable by a motor 120 and a belt drive, whichextends around a pulley (not shown) at the lower end of each drum. Inthe embodiment shown, motor 120 is a servo motor which provides theability to control the precise rotational position of each drum storageassembly so as to make each storage slot in the drum accessible to agripping and storing assembly.

Referring to FIGS. 12 and 13, the gripping and storing assembly includesan elongated tower element 130 which extends for approximately theheight of each drum storage assembly 14. The gripping and storingassembly includes a servo motor 132 which through a gear box 134 drivesa lower pulley (not shown), all located at the base of the tower 130. Adrive belt extends from the base pulley up the tower and around an upperpulley (not shown) located at the top of the tower. Pulleys 136 and 137are used with a counterweight which assists in control over movement ofa gripper support assembly 139.

The gripper support assembly 139 includes a support arm 140 whichextends horizontally outwardly from tower 130. Extending from arm 140 isa mounting plate 142. Rotatably connected to mounting plate 142 is agrip element assembly 143. The grip element assembly 143 includes abelt-driven pulley 144, which is positioned at the upper surface ofmounting plate 142. A belt 145 is capable of moving the grip elementassembly in a rotational direction by means of a servo motor 146.

The grip element assembly also includes two opposing grip arms 148,located below plate 142, which include vertical portions and a narrowear 151 at the lower ends thereof, the two narrow ears 151—151 extendingtoward each other. The grip arms 148 move toward and away from eachother under the control of a motor/belt arrangement, shown at 150.Operation of the motor/belt arrangement 150 permits the grip arms 148 tofirst move away from each other, allowing the ear portions 151—151 to bepositioned beneath the box/item on the loading platform and then to movetoward each other to obtain a firm grasp on the item. Mounted on theundersurface of plate 142 is a linear actuator 152, which is controlledby a motor 154 or an air cylinder. The linear actuator 152 moves backand forth in the axial direction, taking with it the grip elementassembly.

The grip element assembly also includes a pusher arm 156 which iscontrolled by a pneumatic actuator. The pusher arm is located betweengrip arms 148 and in operation moves forward against an item held bygrip arms 148. Positioned in the free end of pusher arm 156 is a pushpin element 158. Push pin 158, when actuated, extends out beyond the endof pusher arm 156 and provides a final force for moving the item intothe correct assigned cell of the drum storage 14.

In operation, the gripping and storing assembly has four degrees offreedom. The gripper support assembly moves up and down tower 130 (thevertical direction) by means of the servomotor/gearbox/belt/pulleys/counterweight arrangement. The balance forthe gripper support assembly is provided by the counterweight, whichmoves up and down, allowing improved control over the gripper supportassembly. The grip arms 148 are moved toward and away from each other bymotor and belt arrangement 151 to grip and release each package/item.The grip element assembly is both rotatable by the motor, belt andpulley arrangement and movable axially along linear actuator 152 by theaction of motor 154. Finally, a pusher arm and extending pin arrangementmove the item from the grip arms 148 into a selected storage slot in adrum storage 14.

It should be understood that while the gripping and storing assemblyshown and described is preferred for the particular present applicationof medications which have been overpackaged, or for other boxedelements, other grasping systems can be used. For instance, a lowprofile vacuum chuck system, whereby a vacuum head portion contacts anitem on the load platform and raises the item by a vacuum (suction)action is an alternative possibility. Elevating pins would not benecessary in such an embodiment. Similar systems are known for otherapplications. It is also possible to use other arrangements, such asmagnetic, where part of the packaging or the item itself is magnetic. Arobotic finger system could be another alternative. There are variousways and mechanisms for picking up medications or other items from aconveyor or a load platform and then placing them into assignedlocations in a storage device.

The system of the present invention also includes two ejector assemblies18, shown in detail in FIG. 14. The ejector assemblies are located nearopposing edges of the system, between two adjacent drum storageelements. Each ejector assembly in the embodiment shown serves two drumstorage units. This could be changed, however. Each ejector assembly 18includes a tower 162, on which is mounted a belt 163 driven by a servomotor 164 and a pulley system 166. Each ejector assembly includes twoejector units 168 and 170, with each ejector unit having two fixedejector arms 172, which are arranged at an angle of 30° relative to eachother in the embodiment shown. The ejector units 168 and 170 movetogether up and down the tower, covering the entire height of the tower,with unit 170 covering an upper portion of the tower and unit 168covering the remaining portion.

At the end of each arm is a sensor 173 which verifies that the desireditem to be ejected is present in the selected slot in the drum storageassembly. If not, an inventory error is noted for the control system. Ifthe item is present, a command is provided and an ejection cylinderextends the arm 172 which pushes the item from the ejection assemblyinto the center of the drum storage device, where it falls down to anoutput conveyor 174. Each pair of drum storage assemblies in theembodiment shown, served by a single ejection assembly, has an outputconveyor located beneath them to carry the item out of the system. Theejection sensor 173 on the arm 172 recognizes that the selected item hasbeen ejected. The ejection cylinder is then withdrawn.

In operation, to eject a selected item from the apparatus, the drumstorage assembly is first rotated so that the cell in the drum storagecontaining the item to be dispensed is in line with an ejection arm fromthe ejection assembly. The ejection cylinder is then activated, pushingthe item into the center of the drum storage device. The conveyortherebeneath, being activated, will move the dispensed item out of thesystem into a container or perhaps onto another conveyor (22 in FIG. 1),which will move the item to another location for further processing,such as loading into a medication cart.

An alternative to the electromechanical arrangement of FIG. 14,involving ejection arms, is an air nozzle arrangement, in which thestored items are removed by air pressure. The air nozzle arrangementwould be particularly effective with bags, blister packs and euclidpacks.

Hence, a system has been described which has the capability of receivingitems, such as medications in bulk, including returned medications,singulating them and then identifying and confirming that they arewithin tolerance. The items are then oriented on a conveyor in theembodiment shown, and then moved to a loading platform, where a gripperand storage assembly, or a vacuum arrangement, moves them into the bulkstorage units. The same system is thus capable of concurrently storingmedications or other elements, including returns, and dispensing themupon command out of the apparatus to a container or a conveyor.

Although a preferred embodiment of the invention has been described forpurposes of illustration, it should be understood that various changes,modifications and substitutions can be made in that embodiment, inaddition to the alternatives discussed above, without departing from thespirit of the invention as defined by the claims which follow.

1. A system for automatically storing and dispensing individualelements, comprising: a bin for temporarily storing a plurality ofindividual elements; apparatus for singulating the individual elementsand for depositing them one by one onto a system conveyor, which inoperation moves the elements to a loading mechanism within the system; aloading mechanism for removing the element from the conveyor andpositioning it so that it is ready to be stored; a mass storageapparatus containing a plurality of individually addressable storagelocations for storage of said elements; an assembly for moving thepositioned elements individually in turn and storing each element in apreselected location in the mass storage apparatus; and at least onedispensing assembly for removing a selected individual element from aknown location in the mass storage apparatus and for moving thedispensed element out of the system.
 2. A system of claim 1, wherein theindividual elements are medical elements.
 3. A system of claim 1,wherein the individual elements are jewelry.
 4. A system of claim 1,wherein the individual elements are hardware items.
 5. A system of claim1, wherein the removing/positioning assembly and the moving/storingassembly operate independently of the dispensing assembly relative tothe mass storage apparatus.
 6. A system of claim 1, wherein theremoving/positioning assembly and the moving/storing assembly arecapable of operating concurrently with the dispensing assembly relativeto the mass storage apparatus.
 7. A system of claim 1, wherein said binincludes a hopper having a gated opening for receiving said individualelements therethrough, wherein the hopper includes at least twodownwardly and inwardly angled walls for urging the received elementsdown to a bottom portion of the hopper.
 8. A system of claim 7,including a stair-stepper mechanism for moving the individual elementsout of the hopper to a start portion of a remainder of the system.
 9. Asystem of claim 8, wherein the stair-stepper mechanism includes twoalternating sets of separate plates, one set being fixed in position,the other set moving, wherein in operation the moving plates move theindividual elements upwardly along a series of successive step-likeportions of the fixed plates.
 10. A system of claim 1, wherein thesingulating system includes a series of four conveyors and a speed-uproller, including a first conveyor which is followed by a speed-uproller; a second conveyor receiving elements from the speed-up roller; athird, vertically oriented conveyor guiding elements from the secondconveyor, the third conveyor extending at approximately a right angle tothe second conveyor; and a fourth conveyor which moves the elementsguided by the third conveyor onto the system conveyor.
 11. A system ofclaim 10, wherein the singulating apparatus includes at least one sensorfor each conveyor portion thereof and wherein the operation of one ofthe singulating conveyors is initiated when a sensor for the nextdownstream conveyor or roller senses that there is no element present atthat location.
 12. A system of claim 1, including means for inspectingthe individual elements when they are deposited onto the systemconveyor.
 13. A system of claim 12, wherein the inspecting meansincludes a movable arm which when actuated moves an item deposited onthe system conveyor into contact with a far wall bounding the systemconveyor, wherein the arm includes a potentiometer element fordetermining whether the element is within predefined standards, so thata damaged element container can be identified.
 14. A system of claim 13,including an actuating member for moving the far wall when the elementis not within the predefined standards, permitting the element to bepushed off the system conveyor and into a first reject deposit member bysaid movable arm.
 15. A system of claim 13, wherein the inspecting meansincludes a pin-like element which is selectively activated to knock downa tall element present on the system conveyor so that it presents alower profile.
 16. A system of claim 1, wherein the inspecting meansincludes means for visually identifying the element and for determiningwhether the element meets preselected criteria.
 17. A system of claim 1,including a scan system located downstream of said inspecting means forreading a barcode on selected surfaces of the element.
 18. A system ofclaim 17, wherein the selected surfaces include the top and sides of theelement.
 19. A system of claim 1, wherein the loading mechanism includesa loading platform upon which the element is moved from the mainconveyor, and a lift platform located therebeneath having pin elementsextending therefrom, wherein in operation the lift platform is activatedsuch that the pins move through corresponding openings in the loadplatform to elevate the element so that it can be conveniently grippedby the removing and storing assembly.
 20. A system of claim 19, whereinthe loading mechanism includes a barcode scanner for scanning a bottomsurface of the element when it is located on the loading platform.
 21. Asystem of claim 20, including a bar member for moving the element backon the main conveyor if no barcode is detected on the element andwherein said element is moved by the main conveyor to a second rejectarea.
 22. A system of claim 19, wherein the moving and storing assemblyincludes a pair of gripping arms which are movable in response to asignal command toward and away from each other to grab the elementelevated on the pins.
 23. A system of claim 22, wherein the moving andstoring assembly includes a tower element and an actuator for moving thegripping arms vertically for approximately the height of the massstorage apparatus, and wherein the moving and storing assembly furtherincludes an actuator for rotating the gripping arms at least through apartial arc, and for moving the gripping arms axially in a straight lineand in the same plane as the rotation thereof.
 24. A system of claim 22,wherein the moving and storing assembly includes a load arm which movesaxially to load the elements into a selected addressable location in themass storage apparatus.
 25. A system of claim 1, wherein the elementsare overpackaged in a box and wherein the system can accommodate atleast four different size boxes.
 26. A system of claim 1, wherein theelements are packaged in a bag.
 27. A system of claim 1, wherein theelements are packaged in a blister pack.
 28. A system of claim 1,wherein the elements are packaged in a euclid pack.
 29. A system ofclaim 1, wherein the moving and storing assembly includes a sensor forrecognizing whether or not said preselected location is vacant prior toactuation of the load arm.
 30. A system of claim 1, wherein thedispensing assembly includes a dispensing tower member, an ejectorassembly mounted for vertical movement on the dispensing tower member,the ejector mechanism including two sets of angled ejector arms, eachset operating independently of the other set and covering a selectedportion of the vertical dimension of the mass storage apparatus.
 31. Asystem of claim 30, wherein the ejector arm moves toward and away fromthe mass storage apparatus, contacting the selected element in an opencell as it moves toward the main storage apparatus, ejecting the storedelement into an open center portion of each mass storage apparatus, andwherein the system further includes a conveyor located beneath the massstorage apparatus for carrying the dispensed elements out of the system.32. A system of claim 1, wherein the mass storage apparatus includesfour upstanding cylindrical storage devices, each storage devicecontaining a plurality of individual storage cells open at the front andrear ends thereof, located around the periphery thereof, wherein thecylindrical storage devices are open at the center thereof, wherein theremoving and storing assembly is located approximately at the center ofthe four storage devices and serves all four devices, and wherein thesystem includes at least two dispensing assemblies, each dispensingassembly serving two adjacent cylindrical storage elements, and whereineach ejector assembly includes an angled ejector assembly for eachcylindrical storage device.